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CN110476239B - Gap filling using reactive annealing - Google Patents

Gap filling using reactive annealing Download PDF

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Publication number
CN110476239B
CN110476239B CN201880021521.1A CN201880021521A CN110476239B CN 110476239 B CN110476239 B CN 110476239B CN 201880021521 A CN201880021521 A CN 201880021521A CN 110476239 B CN110476239 B CN 110476239B
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film
annealing
feature
flowable
plasma
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CN110476239A (en
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A·B·玛里克
P·曼纳
江施施
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Applied Materials Inc
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Applied Materials Inc
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    • H—ELECTRICITY
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    • H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
    • H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
    • H01L21/30—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
    • H01L21/31—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to form insulating layers thereon, e.g. for masking or by using photolithographic techniques; After treatment of these layers; Selection of materials for these layers
    • H01L21/3105—After-treatment
    • H01L21/31051—Planarisation of the insulating layers
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    • H01L21/71—Manufacture of specific parts of devices defined in group H01L21/70
    • H01L21/768—Applying interconnections to be used for carrying current between separate components within a device comprising conductors and dielectrics
    • H01L21/76801—Applying interconnections to be used for carrying current between separate components within a device comprising conductors and dielectrics characterised by the formation and the after-treatment of the dielectrics, e.g. smoothing
    • H01L21/76837—Filling up the space between adjacent conductive structures; Gap-filling properties of dielectrics
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    • H01L21/02123—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing silicon
    • H01L21/02126—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing silicon the material containing Si, O, and at least one of H, N, C, F, or other non-metal elements, e.g. SiOC, SiOC:H or SiONC
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    • H01L21/0214—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing silicon the material containing Si, O, and at least one of H, N, C, F, or other non-metal elements, e.g. SiOC, SiOC:H or SiONC the material being a silicon oxynitride, e.g. SiON or SiON:H
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    • H01L21/02164—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing silicon the material being a silicon oxide, e.g. SiO2
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    • H01L21/02167—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing silicon the material being a silicon carbide not containing oxygen, e.g. SiC, SiC:H or silicon carbonitrides
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    • H01L21/0217—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing silicon the material being a silicon nitride not containing oxygen, e.g. SixNy or SixByNz
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    • H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
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    • H01L21/02107—Forming insulating materials on a substrate
    • H01L21/02109—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates
    • H01L21/02205—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates the layer being characterised by the precursor material for deposition
    • H01L21/02208—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates the layer being characterised by the precursor material for deposition the precursor containing a compound comprising Si
    • H01L21/02211—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates the layer being characterised by the precursor material for deposition the precursor containing a compound comprising Si the compound being a silane, e.g. disilane, methylsilane or chlorosilane
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    • H01L21/02263—Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process deposition from the gas or vapour phase
    • H01L21/02271—Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process deposition from the gas or vapour phase deposition by decomposition or reaction of gaseous or vapour phase compounds, i.e. chemical vapour deposition
    • H01L21/02274—Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process deposition from the gas or vapour phase deposition by decomposition or reaction of gaseous or vapour phase compounds, i.e. chemical vapour deposition in the presence of a plasma [PECVD]
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    • H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
    • H01L21/30—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
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    • H01L21/768—Applying interconnections to be used for carrying current between separate components within a device comprising conductors and dielectrics
    • H01L21/76801—Applying interconnections to be used for carrying current between separate components within a device comprising conductors and dielectrics characterised by the formation and the after-treatment of the dielectrics, e.g. smoothing
    • H01L21/76822—Modification of the material of dielectric layers, e.g. grading, after-treatment to improve the stability of the layers, to increase their density etc.
    • H01L21/76828—Modification of the material of dielectric layers, e.g. grading, after-treatment to improve the stability of the layers, to increase their density etc. thermal treatment

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Abstract

The method for seamless gap filling comprises the following steps: forming a flowable film by PECVD; annealing the flowable film with a reactive anneal to form an annealed film; and hardening the flowable film or annealed film to cure the film. Higher order silanes and plasmas can be used to form flowable films. Reactive annealing may use monosilane or higher silanes. UV hardening or other hardening may be used to cure the flowable film or annealed film.

Description

Gap filling using reactive annealing
Technical Field
The present invention relates generally to methods of depositing thin films. In particular, the present invention relates to a process for forming gap-filling films having a low hydrogen content.
Background
In microelectronic device fabrication, it is desirable for many applications to fill narrow trenches with Aspect Ratios (AR) greater than 10:1 without holes. One application is for Shallow Trench Isolation (STI). For this application, the film needs to be of high quality (e.g., having a wet etch rate ratio of less than 2) throughout the trench with very low leakage. Post-hardening methods of deposited flowable films become difficult as structures shrink in size and aspect ratio increases. Resulting in a film having a varying composition throughout the filled trench.
Amorphous silicon has been widely used as a sacrificial layer in semiconductor manufacturing processes because amorphous silicon can provide good etch selectivity with respect to other films (e.g., silicon oxide, amorphous carbon, etc.). With reduced Critical Dimensions (CDs) in semiconductor fabrication, filling high aspect ratio gaps becomes increasingly sensitive to advanced wafer fabrication. Current metal replacement gate processes involve furnace polysilicon or amorphous silicon dummy gates. Due to the nature of the process, seams are formed in the middle of the Si dummy gate. This seam may be opened during post-processing and cause structural failure.
A flowable film can be deposited to fill the trench without forming a seam. The deposited flowable film has a high hydrogen content that affects film density and quality. Various hardening methods can reduce the hydrogen content and improve the film quality; however, voids occur in the hardened film. Thus, there is a need for a method for gap filling that can provide seamless film growth in high aspect ratio structures.
Disclosure of Invention
One or more embodiments of the present invention are directed to a processing method including: a substrate surface having at least one feature thereon is provided. At least one feature extends a depth from the substrate surface to the bottom surface. At least one feature has a width defined by a first sidewall and a second sidewall. A flowable film is formed on the substrate surface and the first, second, and bottom surfaces of the at least one feature. The flowable film fills the features and is formed substantially without seams. Annealing the flowable film to form an annealed film. The annealed film is hardened to cure the film and form a substantially seamless gap fill.
Additional embodiments of the present invention are directed to a processing method comprising: a substrate surface having at least one feature thereon is provided. At least one feature extends a depth from the substrate surface to the bottom surface. At least one feature has a width defined by the first sidewall and the second sidewall and an aspect ratio of greater than or equal to about 25:1. A flowable silicon film is formed on the substrate surface and the first, second and bottom surfaces of the at least one feature by PECVD. The flowable film fills the features and is formed substantially without seams. The flowable film is treated with a post-treatment process to form an annealed film. The annealed film is hardened to cure the film and form a substantially seamless gap fill.
A further embodiment of the present invention is directed to a processing method comprising: a substrate surface having at least one feature thereon is provided, the at least one feature extending a depth from the substrate surface to the bottom surface. At least one feature has a width defined by the first sidewall and the second sidewall and an aspect ratio of greater than or equal to about 25:1. A flowable silicon film is formed on the substrate surface and the first, second and bottom surfaces of the at least one feature by a PECVD process. The flowable film fills the features and is formed substantially without seams. The PECVD process includes a polysilicon precursor and a plasma including a plasma gas. The polysilicon precursor includes one or more of disilane, trisilane, tetrasilane, neopentasilane (neopentasilane), or cyclohexasilane (cyclohexasilane). The plasma gas includes He, ar, kr, H 2 、N 2 、O 2 、O 3 Or NH 3 One or more of the following. The plasma has a power of less than or equal to about 200W. The PECVD process occurs at a temperature of less than or equal to about 100 ℃. The flowable film is exposed to a post-treatment process that includes exposure to an annealing reactant at an annealing temperature and an annealing pressure. The annealing reactant includes one or more of monosilane or disilane. The annealing temperature is in the range of about 100 ℃ to about 400 ℃. The annealing pressure is in the range of about 100Torr to about 500 Torr. The annealed film is exposed to UV hardening to cure the film and form a substantially seamless gap fill.
Brief description of the drawings
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 illustrates a cross-sectional view of a substrate feature in accordance with one or more embodiments of the invention;
FIG. 2 shows a cross-sectional view of the substrate feature of FIG. 1 with a flowable film thereon; and
fig. 3 shows a cross-sectional view of the substrate feature of fig. 1 with an annealed film thereon.
Detailed Description
Before explaining several exemplary embodiments of the invention, it is to be understood that the invention is not limited in its application to the details of construction or to the process steps set forth in the following description. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
"substrate" is used herein to refer to any substrate or surface of material formed on a substrate upon which a film process may be performed during a manufacturing process. For example, the substrate surface on which the process may be performed includes materials such as silicon, silicon oxide, strained silicon, silicon-on-insulator (SOI), carbon doped silicon oxide, amorphous silicon, doped silicon, germanium, gallium arsenide, glass, sapphire, and any other material, such as metals, metal nitrides, metal alloys, and other conductive materials, depending on the application. The substrate includes, but is not limited to, a semiconductor wafer. The substrate may be exposed to a pretreatment process to polish, etch, reduce, oxidize, hydroxylate, anneal, UV harden, electron beam harden, and/or bake the substrate surface. In addition to film processing directly on the surface of the substrate itself, in the present invention, any disclosed film processing steps may also be performed on an underlying layer formed on the substrate as disclosed in more detail later, and the term "substrate surface" is intended to include such underlying layer as indicated in the context. Thus, for example, in the case where a film/layer or a portion of a film/layer has been deposited over a substrate surface, the exposed surface of the newly deposited film/layer becomes the substrate surface.
Embodiments of the present disclosure provide methods of depositing films (e.g., amorphous silicon) in high Aspect Ratio (AR) structures having small dimensions. Certain embodiments advantageously provide a method that involves a cyclical deposition process that may be performed in a cluster tool environment. Certain embodiments advantageously provide a seamless high quality amorphous silicon film to fill high AR trenches with small dimensions.
One or more embodiments of the present disclosure are directed to a process that deposits a flowable amorphous silicon film that can fill high aspect ratio structures (e.g., AR > 8:1) having Critical Dimensions (CD) less than 20 nm. The film may be deposited using a polysilane precursor with low temperature (e.g., <100 ℃) Plasma Enhanced Chemical Vapor Deposition (PECVD). The plasma power of the process may be maintained below about 200W or 300W to reduce the reaction kinetics and obtain haze-free films. The chamber body temperature may also be controlled by controlling the heat exchanger temperature. Disilane, trisilane, tetrasilane, neopentasilane or cyclohexasilane are typical polysilanes that may be used. Post-deposition treatments such as UV hardening may be performed to stabilize the film. Embodiments of the process allow for the preparation of flowable SiC and SiCN films by adding hydrocarbons and nitrogen sources to the flowable Si process. Furthermore, flowable metal silicide (WSi, taSi, niSi) can also be deposited by adding suitable metal precursors to the flowable silicon process.
Fig. 1 shows a partial cross-sectional view of a substrate 100 having features 110. The figures show a substrate with individual features for illustrative purposes; however, one skilled in the art will appreciate that more than one feature may be present. The shape of the features 110 may be any suitable shape including, but not limited to, trenches and cylindrical vias. As used herein, the term "feature" means any intentional surface irregularity. Suitable examples of features include, but are not limited to, trenches having a top, two sidewalls, and a bottom, and spikes having a top and two sidewalls. The features may have any suitable aspect ratio (ratio of the depth of the feature to the width of the feature). In certain embodiments, the aspect ratio is greater than or equal to about 5:1, 10:1, 15:1, 20:1, 25:1, 30:1, 35:1, or 40:1.
The substrate 100 has a substrate surface 120. At least one feature 110 forms an opening in the substrate surface 120. The features 110 extend a depth D from the substrate surface 120 to the bottom surface 112. The feature 110 has a first sidewall 114 and a second sidewall 116, the first sidewall 114 and the second sidewall 116 defining a width W of the feature 110. The open area formed by the sidewalls and bottom may also be referred to as a gap.
One or more embodiments of the present disclosure are directed to a processing method in which a substrate surface having at least one feature thereon is provided. As used herein, the term "providing" means that the substrate is placed in a location or environment for further processing.
As shown in fig. 2, a flowable film 150 is formed on the substrate surface 120 and the first, second, and bottom surfaces 114, 116, 112 of the at least one feature 100. The flowable film 150 fills the at least one feature 110 such that a substantially seamless formation occurs. A seam is a gap formed in the feature, between the sidewalls of the feature 110 but not necessarily in the middle. As used herein, the term "substantially seamless" means that any gap in the film formed between the sidewalls is less than about 1% of the cross-sectional area of the sidewalls.
The flowable film 150 can be formed by any suitable process. In certain embodiments, forming the flowable film is accomplished by Plasma Enhanced Chemical Vapor Deposition (PECVD). In other words, the flowable film may be deposited by a plasma enhanced chemical vapor deposition process.
The PECVD process of certain embodiments includes exposing the substrate surface to a reactive gas. The reactant gas may comprise a mixture of one or more substances. For example, the reactive gas may include a silicon precursor and a plasma gas. The plasma gas may be any suitable gas that can be ignited to form a plasma and/or can act as a carrier or diluent for the precursor.
In certain embodiments, the silicon precursor includes higher silanes, also referred to as polysilicon species, and is referred to as a polysilicon precursor. The polysilicon precursors of certain embodiments include one or more of disilane, trisilane, tetrasilane, neopentasilane, and/or cyclohexasilane. In one or more embodiments, the polysilicon precursor includes tetrasilane. In certain embodiments, the polysilicon precursor consists essentially of tetrasilane. As used herein, the term "consisting essentially of …" means that the silicon species of the reactant gas is composed of about 95% or more of the specified species on a molar basis (molar basis). For example, a polysilicon precursor consisting essentially of tetrasilane means that the silicon species of the reaction gas is greater than or equal to about 95% tetrasilane on a molar basis.
In certain embodiments, the plasma gas comprises He, ar, H 2 、Kr、N 2 、O 2 、O 3 Or NH 3 One or more of the following. The plasma gas of some embodiments serves as a diluent or carrier gas for the reactive species (e.g., polysilicon species) in the reactive gas.
The plasma may be generated or ignited within the processing chamber (e.g., a direct plasma) or may be generated outside of the processing chamber and flowed into the processing chamber (e.g., a remote plasma). The plasma power may be maintained at a low enough power to prevent reduction of polysilicon species to silane and/or to minimize or prevent haze formation in the film. In certain embodiments, the plasma power is less than or equal to about 300W. In one or more embodiments, the plasma power is less than or equal to about 250W, 200W, 150W, 100W, 50W, or 25W. In certain embodiments, the plasma power is in the range of about 10W to about 200W, or in the range of about 25W to about 175W, or in the range of about 50W to about 150W.
The flowable film 150 can be formed at any suitable temperature. In certain embodiments, the flowable film 150 is formed in a temperature in a range of about-100 ℃ to about 50 ℃, or in a range of about-75 ℃ to about 40 ℃, or in a range of about-50 ℃ to about 25 ℃, or in a range of about-25 ℃ to about 0 ℃. The temperature may be kept low to maintain the thermal budget formation of the device. In certain embodiments, forming the flowable film occurs at a temperature of less than about 50 ℃, 40 ℃, 30 ℃, 20 ℃, 10 ℃, 0 ℃, -10 ℃, -20 ℃, -30 ℃, -40 ℃, -50 ℃, -60 ℃, -70 ℃, -80 ℃, or-90 ℃.
The flowable film 150 can be formed at any suitable pressure. In certain embodiments, the pressure used to form the flowable film 150 is in the range of about 0.5Torr to about 50Torr, or in the range of about 0.75Torr to about 25Torr, or in the range of about 1Torr to about 10Torr, or in the range of about 2Torr to about 8Torr, or in the range of about 3Torr to about 6 Torr.
Can be adjusted by changing the composition of the reaction gasComposition of the whole flowable film. In certain embodiments, the flowable film comprises one or more of SiN, siO, siC, siOC, siON, siCON. To form the oxygen-containing film, the reactant gas may include, for example, one or more of oxygen, ozone, or water. For forming the nitrogen-containing film, the reaction gas may include, for example, ammonia, hydrazine, NO 2 Or N 2 One or more of the following. To form the carbon-containing film, the reaction gas may include, for example, one or more of propylene and acetylene. Those skilled in the art will appreciate that other combinations of materials may be included in the reactant gas mixture to alter the composition of the flowable film.
In certain embodiments, the flowable film comprises a metal silicide. The reactive gas mixture may include, for example, a precursor including one or more of tungsten, tantalum, or nickel. Other metal precursors may be included to alter the composition of the flowable film.
Referring to fig. 3, after the flowable film 150 is formed, the flowable film 150 may be treated with a reactive annealing process to prevent hole formation in the final gap-fill film. The flowable film 150 can be exposed to a reactive gas under annealing conditions to form an annealed film 155. Treating the flowable film 150 with a reactive anneal may also be referred to as post-treatment. As used herein, the term "post-treatment" refers to a process that occurs after the formation of the flowable film 150. When various reactants are used to adjust the composition of the flowable film 150, treatment of the flowable film results in a change in the composition of the flowable film or a change in the relative percentages of atoms in the flowable film. For example, if flowable film 150 is 80% Si and 20% N on an atomic basis, then processing may result in a film that is 50% Si and 50% N on an atomic basis. In certain embodiments, exposure to the reactive annealing process results in a film having a lower hydrogen content than the flowable film 150 prior to annealing. In certain embodiments, the hydrogen content is reduced by greater than or equal to about 30%, 40%, 50%, 60%, 70%, 80, or 90% relative to the content in the flowable film 150.
The reactive annealing process includes exposing the substrate to an annealing reactant at a suitable annealing temperature and annealing pressure. The annealing reactant of certain embodiments includes a silicon compound. In one or more embodiments, the annealing reactant includes one or more of monosilane, disilane, trisilane, or higher silanes (i.e., having more than three silicon atoms). In certain embodiments, the annealing reactant is co-flowed with a diluent or carrier gas. For example, the annealing reactant may comprise silane in an argon carrier gas. In certain embodiments, the carrier gas is also reactive and helps harden the flowable film 150 without forming holes. In certain embodiments, the annealing reactant includes the same silicon species as the precursor used in the formation of flowable film 150. In certain embodiments, the annealing reactant includes a substance different from the reactant used in the formation of the flowable film 150.
The reactive anneal of certain embodiments occurs in the absence of a plasma. In certain embodiments, a plasma may be generated during the reactive annealing process. The plasma may be formed using an annealing reactant or a post-treatment plasma species different from the annealing reactant. For example, the annealing reactant may be flowed with a diluent or carrier gas that is used to ignite a plasma (e.g., argon). The annealing reactant may flow or pulse continuously into the process chamber.
The annealing temperature during the reactive anneal of certain embodiments is in the range of about 100 ℃ to about 500 ℃, or in the range of about 100 ℃ to about 400 ℃, or in the range of about 125 ℃ to about 375 ℃, or in the range of about 150 ℃ to about 350 ℃, or in the range of about 175 ℃ to about 325 ℃, or in the range of about 200 ℃ to about 300 ℃. In certain embodiments, the annealing temperature is greater than or equal to about 100 ℃, 150 ℃, 200 ℃, 250 ℃, 300 ℃, 350 ℃, 400 ℃, 450 ℃, or 500 ℃.
The annealing pressure during the reactive annealing process may be in the range of about 100Torr to about 500Torr, or in the range of about 150Torr to about 450Torr, 200Torr to about 400Torr. In certain embodiments, the annealing pressure during the reactive anneal is greater than or equal to about 50Torr, 100Torr, 150Torr, 200Torr, 250Torr, 300Torr, or 350Torr.
After formation of the flowable film 150 or annealed film 155, the film is hardened to cure the flowable film 150 or annealed film 155 and form a substantially seamless gap fill. In certain embodiments, the flowable film 150 or annealed film 155 is hardened by exposing the film to a UV hardening process. The UV hardening process may occur at a temperature in the range of about 10 ℃ to about 550 ℃. The UV hardening treatment may occur for any suitable period of time necessary to sufficiently cure the flowable film 150 or annealed film 155. In certain embodiments, UV hardening occurs for less than or equal to about 10 minutes, 9 minutes, 8 minutes, 7 minutes, 6 minutes, 5 minutes, 4 minutes, 3 minutes, 2 minutes, or 1 minute.
In certain embodiments, hardening the flowable film 150 or annealed film 155 includes exposure to a plasma or electron beam. Plasma exposure to harden the film includes a plasma separate from the PECVD plasma or post-processing plasma. The plasma species and the processing chamber may be the same or different, and the plasma hardening may be a different step than the PECVD process or post-processing plasma. In certain embodiments, the post-processing plasma processes and hardens the flowable film 150 at the same time to form a hardened annealed film 155.
Certain embodiments of the present disclosure provide hardened gap-filling films with low hydrogen content. In certain embodiments, after hardening the film, the gap-fill film has a hydrogen content of less than or equal to about 10 atomic percent. In certain embodiments, the hardened film has a hydrogen content of less than or equal to about 5 atomic percent, 4 atomic percent, 3 atomic percent, 2 atomic percent, or 1 atomic percent.
According to one or more embodiments, the substrate is subjected to a treatment before and/or after forming this layer. This process may be performed in the same chamber or in one or more separate processing chambers. In certain embodiments, the substrate is moved from the first chamber to a separate second chamber for further processing. The substrate may be moved directly from the first chamber to a separate processing chamber, or the substrate may be moved from the first chamber to one or more transfer chambers and then to a separate processing chamber. Thus, the processing apparatus may comprise a plurality of chambers in communication with the transfer chamber. Such devices are also referred to as "cluster tools" or "cluster systems" or the like.
In general, a cluster tool is a modular system that includes a plurality of chambers that perform various functions including: substrate center finding and positioning, degassing, annealing, deposition and/or etching. According to one or more embodiments, the cluster tool includes at least a first chamber and a central transfer chamber. The central transfer chamber may house robots that can transfer substrates between and among the process chambers and the load lock chamber. The transfer chamber is typically maintained under vacuum conditions and provides an intermediate stage for transferring substrates from one chamber to another and/or to a load lock chamber positioned at the front end of the cluster tool. Two well-known cluster tools applicable to the present invention areAndboth available from applied materials, inc. of Santa Clara, calif. However, the exact arrangement and combination of chambers may vary for the purpose of performing particular steps of the processes described herein. Other processing chambers that may be used include, but are not limited to: cyclic Layer Deposition (CLD), atomic Layer Deposition (ALD), chemical Vapor Deposition (CVD), physical Vapor Deposition (PVD), etching, pre-cleaning, chemical cleaning, thermal processing such as RTP, plasma nitridation, outgassing, positioning, hydroxylation, and other substrate processes. By performing the process in a chamber on the cluster tool, contamination of the surface of the substrate by atmospheric impurities can be avoided without oxidation prior to deposition of subsequent films.
In accordance with one or more embodiments, the substrate is continuously under vacuum or "load lock" conditions and is not exposed to ambient air as it moves from one chamber to the next. The transfer chamber is thus "pumped down" under vacuum and under vacuum pressure. An inert gas may be present in the process chamber or the transfer chamber. In certain embodiments, an inert gas is used as a purge gas to remove some or all of the reactants. According to one or more embodiments, purge gas is injected at the outlet of the deposition chamber to prevent the movement of reactants from the deposition chamber to the transfer chamber and/or additional processing chambers. Thus, the flow of inert gas forms a curtain of gas at the outlet of the chamber.
The substrate may be processed in a single substrate deposition chamber where a single substrate is loaded, processed, and unloaded before another substrate is processed. The substrates may also be processed in a continuous manner, similar to a conveyor system, in which multiple substrates are individually loaded into a first portion of the chamber, moved through the chamber, and unloaded from a second portion of the chamber. The shape of the chamber and associated conveyor system may form a straight path or a curved path. Further, the processing chamber may be a rotating gantry in which multiple substrates move about a central axis and are exposed to deposition, etching, annealing, cleaning, etc. processes throughout the path of the rotating gantry.
During processing, the substrate may be heated or cooled. This heating or cooling may be accomplished by any suitable means including, but not limited to, changing the temperature of the substrate support and flowing a heated or cooled gas to the substrate surface. In certain embodiments, the substrate support includes a heater/cooler that can be controlled to conductively change the substrate temperature. In one or more embodiments, the gas being used (either a reactive gas or an inert gas) is heated or cooled to locally change the substrate temperature. In some embodiments, a heater/cooler is positioned within the chamber adjacent to the substrate surface to convectively change the substrate temperature.
The substrate may also be stationary or rotated during processing. The rotating substrate may be rotated continuously or stepwise. For example, the substrate may be rotated throughout the process, or the substrate may be rotated a small amount between exposures to different reactive or purge gases. Rotating the substrate (continuously or stepwise) during processing can help to produce a more uniform deposition or etch by minimizing effects such as localized variations in gas flow geometry.
Reference in this specification to "one embodiment," "certain embodiments," "one or more embodiments," or "an embodiment" means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrases "in one or more embodiments," "in some embodiments," "in one embodiment (in one embodiment)" or "in an embodiment" in various places throughout this specification are not necessarily referring to the same embodiment of the invention. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It will be apparent to those skilled in the art that various modifications and variations can be made in the method and apparatus of the present invention without departing from the spirit or scope of the invention. It is therefore intended that the present invention encompass modifications and variations as fall within the scope of the appended claims and their equivalents.

Claims (20)

1. A method of processing comprising the steps of:
providing a substrate surface having at least one feature thereon, the at least one feature extending a depth from the substrate surface to a bottom surface, the at least one feature having a width defined by a first sidewall and a second sidewall;
forming a flowable film on the substrate surface and the first, second and bottom surfaces of the at least one feature, the flowable film being formed and filling the feature at a temperature of less than-10 ℃ and being formed substantially seamlessly; and
annealing the flowable film by exposing the film to an annealing reactant comprising one or more of a disilane, trisilane, or higher silane to form an annealed film; and
the annealed film is hardened to cure the film and form a substantially seamless gap fill.
2. The process of claim 1, wherein forming the flowable film comprises Plasma Enhanced Chemical Vapor Deposition (PECVD).
3. The processing method of claim 2, wherein the PECVD includes a polysilicon precursor and a plasma, the plasma including a plasma gas.
4. The processing method of claim 3, wherein the polysilicon precursor comprises one or more of: disilane, trisilane, tetrasilane, neopentasilane or cyclohexasilane.
5. The process of claim 3 wherein the plasma gas comprises He, ar, kr, H 2 、N 2 、O 2 、O 3 Or NH 3 One or more of the following.
6. The process of claim 5, wherein the plasma has a power of less than 300W.
7. The process of claim 5 wherein the plasma is a direct plasma.
8. The process of claim 1, wherein forming the flowable film occurs at a temperature of less than 100 ℃.
9. The process of claim 1, wherein hardening the annealed film comprises UV hardening.
10. The process of claim 9, wherein the UV hardening occurs at a temperature in the range of 10 ℃ to 550 ℃.
11. The process of claim 2, wherein hardening the annealed film comprises exposing the annealed film to a plasma and/or electron beam separate from the PECVD.
12. A method of treatment as claimed in claim 3, wherein the flowable film comprises one or more of SiN, siO, siC, siOC, siON, siCON.
13. The treatment method of claim 12, wherein the PECVD further comprises one or more of propylene, acetylene, ammonia, oxygen, ozone, or water.
14. The process of claim 1, wherein annealing the flowable film comprises exposing the flowable film to an annealing reactant at an annealing temperature and an annealing pressure.
15. The process of claim 14, wherein the annealing reactant comprises disilane.
16. The process of claim 14, wherein the annealing temperature is in the range of 100 ℃ to 400 ℃.
17. The processing method of claim 14, wherein the annealing pressure is in the range of 100Torr to 500 Torr.
18. A method of processing, comprising:
providing a substrate surface having at least one feature thereon, the at least one feature extending a depth from the substrate surface to a bottom surface, the at least one feature having a width defined by a first sidewall and a second sidewall and an aspect ratio of greater than or equal to 25:1;
forming a flowable silicon film by PECVD on the substrate surface and the first, second and bottom surfaces of the at least one feature at a temperature of less than-10 ℃, the flowable silicon film filling the feature and being formed substantially without seams;
annealing the flowable silicon film with a post-treatment process by exposing the film to an annealing reactant comprising one or more of a disilane, trisilane, or higher silane to form an annealed film; and
the annealed film is hardened to cure the film and form a substantially seamless gap fill.
19. The processing method of claim 18, wherein the PECVD comprises a polysilicon precursor comprising one or more of disilane, trisilane, tetrasilane, neopentasilane, or cyclohexasilane and a plasma comprising a plasma gas comprising He, ar, kr, H 2 、N 2 、O 2 、O 3 Or NH 3 And the post-treatment process includes exposure to an annealing reactant including disilane.
20. A method of processing, comprising:
providing a substrate surface having at least one feature thereon, the at least one feature extending a depth from the substrate surface to a bottom surface, the at least one feature having a width defined by a first sidewall and a second sidewall and an aspect ratio of greater than or equal to 25:1;
forming a flowable silicon film on the substrate surface and the first, second and bottom surfaces of the at least one feature by a PECVD process at a temperature of less than-10 ℃ that fills the feature substantially without seam formation, the PECVD process comprising a polysilicon precursor comprising one or more of disilane, trisilane, tetrasilane, neopentasilane or cyclohexasilane and a plasma comprising a plasma gas comprising He, ar, kr, H 2 、N 2 、O 2 、O 3 Or NH 3 The plasma having a power of less than or equal to 200W and the PECVD process occurring at a temperature of less than or equal to 100 ℃;
exposing the flowable silicon film to a post-treatment process to form an annealed film, the post-treatment process comprising an annealing reactant comprising one or more of monosilane or disilane at an annealing temperature in the range of 100 ℃ to 400 ℃ and an annealing pressure in the range of 100Torr to 500 Torr; and
the annealed film is exposed to UV hardening to cure the film and form a substantially seamless gap fill.
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